JP2011005750A - Molding method and molding apparatus of foamed resin molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a molding method and a molding apparatus of a foamed resin molding, wherein the sheet thickness of a product is freely set, and the appearance is made excellent by eliminating molding defect like silver streak, uneven foaming and irregularity defect.SOLUTION: An extruding unit 60 and a die 61 are set above a molding mold 50 consisting of a cavity mold 51 and a core mold 52, a foamed resin sheet S is downwardly extruded from the die, and in a suspended state, fed into the opened cavity mold 51 and core mold 52, then the molding mold 50 is clamped to press-mold a foamed resin base material 31 into a required shape. Molten resin M is injected and filled into a recessed part 522 formed in a molding face of the core mold 52 from an injection unit 53 continuously set to the core mold 52 through a resin passage 521, thereby functional resin members 32, 33 are fused and integrated at given positions on the rear face of the resin base material 31.

Description

  The present invention relates to a molding method and a molding apparatus for a foamed resin molded product, and in particular, the foaming ratio can be freely set, and molding defects such as silver streak, foam unevenness, unevenness (surface defect commonly referred to as slick skin), etc. The present invention relates to a molding method and a molding apparatus for a foamed resin molded product, which can easily and inexpensively produce a foamed resin molded product with improved appearance performance by eliminating the problem and enabling a sharp shape.

  FIG. 11 shows an automotive door trim 1 mounted on the interior side of a door panel (not shown). Since this door trim 1 is lightweight, has excellent impact resistance, and is inexpensive, polypropylene ( A foamed resin molded product obtained by molding a foamed resin material in which a foaming agent is mixed into a PP) resin into a required shape is often used. Further, the door trim 1 is integrally formed with an armrest portion 1a that bulges toward the indoor side, and an opening 1b of a door pocket is opened below the armrest portion 1a so as to accommodate equipment. In addition, a speaker grill 1c is provided integrally with or separately from the door trim 1 on the front side of the door pocket.

  And the conventional molding method which shape | molds the door trim 1 which uses this kind of foamed resin molded product in a required shape is demonstrated below. First, as shown in FIG. 12, a molding apparatus 2 to be used is composed of a cavity mold 3 and a core mold 4 that can be clamped and opened with each other. An injection unit 5 as a supply system is provided continuously, and the foamed resin material M supplied from the injection unit 5 is injected and filled into the cavity C formed when the cavity mold 3 and the core mold 4 are clamped. The Further, in order to properly maintain the internal pressure in the cavity C, a pressure increasing tank 6 is provided, and factory air is supplied from the pressure increasing tank 6 through the air piping 6a into the cavity C through the air inlet 6b of the core mold 4. The

  Next, each step of molding the door trim 1 using the molding apparatus 2 will be described. First, as shown in FIG. 12, when the cavity mold 3 and the core mold 4 are clamped, factory air is filled into the cavity C from the pressure increasing tank 6 through the air piping 6a and the air inlet 6b. Then, as shown in FIG. 13, the foamed resin material M is injected and filled into the cavity C through the resin passage 5 a provided in the cavity mold 3 from the injection unit 5. At this time, since the cavity C is filled with factory air in advance, foaming is suppressed, and the foamed resin material M spreads to every corner of the cavity C in a state where no foaming gas is emitted. Further, FIG. 14 shows a state in which the injection of the foamed resin material M is completed in the cavity C. At this time, surplus air in the mold is discharged outside from the PL or the shear. Next, as shown in FIG. 15, after the air remaining in the mold is discharged to the outside through the air discharge port 6c by a vacuum suction mechanism or the like, the core is adjusted in order to adjust the target foaming ratio as shown in FIG. The mold 4 is moved backward in the direction of the arrow in FIG. 16 to complete the foaming reaction. As described above, Patent Document 1 discloses in detail the method of injecting and filling the foamed resin material M into the cavity C and then increasing the mold clearance to cause the foaming reaction.

JP 2002-120252 A

  Thus, in the conventional molding method of the foamed resin molded product applied to the conventional door trim 1, after the foamed resin material M is injected and filled into the cavity C, the core mold 4 is retracted in the mold opening direction to mold clearance. Since the foaming ratio is increased and the foaming magnification is limited, there is a limit to the firing ratio, and it is impossible to increase the expansion ratio to about 2 times or more. If an attempt is made to increase the foaming ratio more than necessary, problems such as R dripping may occur. . Furthermore, since the core mold 4 is moved backward, the mold clearance cannot be set thin, it is difficult to adjust the thickness of the product, there is a problem in the degree of freedom in forming, and air is supplied into the cavity C Since foaming is performed while adjusting the pressure, it has been pointed out that problems such as silver streak, foam unevenness, irregularities and the like are easily induced and it is difficult to maintain good appearance performance.

  The present invention has been made in view of such circumstances, and is a method and apparatus for molding a foamed resin molded product that is molded along the shape of a cavity in a molding die. It is an object of the present invention to provide a foamed resin molded product molding method and a molding apparatus capable of easily and inexpensively molding a foamed resin molded product having excellent appearance performance as well as a product sheet thickness that can be freely set. To do.

  In order to solve the above-mentioned problems, the present inventors, as a result of earnest research, extruded the foamed resin sheet downward from the extrusion unit and the die into a sheet shape, and supplied the foamed resin sheet in a hanging shape into the molding die. Furthermore, by forming this sheet-like foamed resin sheet into a product shape by clamping a molding die, it is possible to effectively solve problems in appearance such as R sagging, silver streak, foam unevenness, irregularities and the like. Attention was paid to the completion of the present invention.

  That is, the present invention relates to a foamed resin base material obtained by press-molding a foamed resin sheet into a required shape by clamping a molding die comprising a cavity mold and a core mold, and a functional resin on the back surface of the foamed resin base material. In a method for molding a foamed resin molded product obtained by fusing and integrating members, a foamed resin sheet is extruded downward from an extrusion unit and a die set above a molding die, and a cavity mold and a core mold are formed. When in the open state, the foamed resin sheet is suspended in the space to supply the foamed resin sheet into the molding die, and the cavity mold and core with the driving direction set to the horizontal direction From the press molding process of the foamed resin base material that molds the foamed resin sheet into the mold surface shape of the molding die by clamping the mold and the injection unit connected to the core mold Injection molding process of a functional resin member in which a molten resin is injected and filled into a recess provided on the core mold surface through a fat passage, and the functional resin member is fused and integrated at a predetermined position on the back surface of the foamed resin base material. It is characterized by the following.

  Further, the molding apparatus used in the method of the present invention is a foamed material comprising a foamed resin base material that is press-molded into a predetermined shape and a functional resin member that is fused and integrated at a predetermined position on the back surface of the foamed resin base material. In the molding apparatus for a resin molded product, the molding apparatus includes an extrusion unit and a die that can extrude the foamed resin sheet downward and a foamed resin sheet that is extruded downward from the die. The mold is composed of a cavity mold and a core mold in which the drive direction that can be press-molded into a required shape is set in the horizontal direction. An injection unit is connected to the core mold, and through a resin passage inside the core mold. The concave portion into which the molten resin from the injection unit is injected and filled is provided at a position corresponding to the functional resin member on the core mold surface.

  Here, the molding die is configured such that the cavity mold on the movable side and the core mold on the fixed side are clamped together and arranged so that the mold can be opened, and the movable direction of the cavity mold on the movable side Is set horizontally. In other words, the cavity mold moves back and forth in the horizontal direction by a predetermined stroke by driving the connected hydraulic cylinder. On the other hand, an injection unit is connected to the core mold, and the molten resin supplied from the injection unit is injected and filled into a groove formed on the mold surface of the core mold through a resin passage such as a hot runner and a gate. Furthermore, a hot blade is formed along the peripheral edge of the parting surface with respect to the mold surface of the core cavity mold, and this hot blade cuts and removes the surplus portion of the foamed resin sheet as an end material. On the other hand, an extrusion unit and a die for supplying the foamed resin sheet in a suspended state in the molding die are provided above the molding die.

Therefore, the method of the present invention using the above-described molding apparatus is roughly divided into the following three steps.
(1) Foamed resin sheet extrusion process (2) Foamed resin substrate press molding process (3) Functional resin member injection molding process

(1) Extruding step of foamed resin sheet After extruding a required amount of foamed resin sheet downward from the extrusion unit and the die, the sheeting from the die is stopped until the molding is completed. The foaming ratio is controlled during the extrusion process of the foamed resin sheet. The extrusion unit and the die are positioned above the molding die, and the foamed resin sheet supplied from the die hangs downward, so that a separate sheet material holding mechanism is not required. Since the draw down phenomenon does not occur as compared with the case where it is supplied horizontally, the moldability can be improved and it can be supplied into the molding die easily and inexpensively.

(2) Press molding process of foamed resin base material If the foamed resin sheet is supplied into the mold, the mold (cavity mold, core mold) is clamped, and the surplus part of the foamed resin sheet is the periphery of the mold. It is cut and removed by a hot blade provided in the part. In this press molding process, the foamed resin sheet is shaped into a product shape, and a foamed resin base material having a desired product plate thickness is molded into a required shape. The drawing pattern may be transferred to the surface of the product by attaching a vacuum suction mechanism to the molding die.

(3) Injection molding process of functional resin member At the same time as the press molding of the foamed resin base material or at a time difference from the press molding, the molten resin is fed from the injection unit connected to the core mold to the core type resin passage (hot runner , Gate) is supplied into a groove portion provided on the core mold surface, and a functional resin member such as a boss and a clip seat is integrated on the back surface of the foamed resin base material by heat fusion. And if shaping | molding is completed, after opening a shaping | molding metal mold | die and removing a molded article, what is necessary is just to perform a piercing cut process etc. if desired.

  Thus, according to the method of the present invention, since the foamed resin sheet is supplied from the extrusion unit and the die into the molding die in a suspended state, the expansion ratio can be freely controlled when the foamed resin sheet is extruded. Furthermore, when the foamed resin sheet is shaped into the product shape by clamping the molding die, the shape is shaped into the product shape by pressing, so that R droop can be eliminated and the plate thickness can be freely set by the mold clearance. Furthermore, by shaping the foamed resin sheet, it is possible to eliminate defects in appearance such as silver streak, foaming unevenness, irregularities and the like.

  Further, according to the method of the present invention, since the foamed resin sheet is supplied from the extrusion unit and the die into the molding die in a suspended state, for example, compared with the case where the sheet material is supplied in a horizontal state, the sheet material holding mechanism is reduced. This eliminates the necessity of simplifying the mold structure, avoiding the draw-down phenomenon, and improving the molding performance.

  Next, in a more preferred embodiment of the present invention, a heater is provided between the extrusion unit and the die and the molding die, and the foamed resin sheet supplied in a suspended form from the extrusion unit and the die is arbitrarily heated by the heater. The molding is characterized in that the foamed resin sheet foamed up to a magnification is dropped in a molding die. The heating temperature by the heater is set to about 200 ° C. And according to this embodiment, the expansion ratio of the foamed resin sheet can be controlled more freely.

  As described above, according to the method and apparatus for molding a foamed resin molded product according to the present invention, the foaming ratio of the foamed resin sheet supplied from the extrusion unit and the die can be freely controlled, so that the product plate thickness and cushion performance Etc. can be set appropriately.

  Furthermore, according to the molding method and molding apparatus of the foamed resin molded product according to the present invention, the R sag of the product can be eliminated by press-molding the foamed resin sheet in the molding die, and the product appearance is silver. Streaks, foaming irregularities, irregularities, etc. do not occur, and foamed resin molded products with good appearance performance can be molded, and the product plate thickness can be set freely by mold clearance, improving the degree of modeling freedom Various effects are possible.

  Further, according to the method of the present invention, since the foamed resin sheet is supplied in a suspended state from the extrusion unit and the die into the molding die, for example, the sheet material holding mechanism is more compared to the case where the sheet material is supplied in a horizontal state. This eliminates the need to simplify the mold structure, avoid the draw-down phenomenon, and improve the molding performance.

It is a front view which shows the door trim for motor vehicles provided with the door trim lower shape | molded by applying the method of this invention. It is the II-II sectional view taken on the line in FIG. It is explanatory drawing which shows schematic structure of 1st Example of the shaping | molding apparatus used for this invention method. It is explanatory drawing which shows the extrusion process of the foamed resin sheet in this invention method. It is explanatory drawing which shows the press molding process of the foamed resin base material in this invention method. It is explanatory drawing which shows the injection molding process of the functional resin member in this invention method. It is explanatory drawing which shows schematic structure of 2nd Example of the shaping | molding apparatus used for this invention method. It is explanatory drawing which shows the extrusion of a foamed resin sheet and the heating process in the shaping | molding method of the foamed resin molded product which uses the shaping | molding apparatus shown in FIG. It is explanatory drawing which shows the press molding process of the foamed resin base material in the shaping | molding method of the foamed resin molded product which uses the shaping | molding apparatus shown in FIG. It is explanatory drawing which shows the injection molding process of the functional resin member in the shaping | molding method of the foamed resin molded product which uses the shaping | molding apparatus shown in FIG. It is a front view which shows the conventional door trim. It is explanatory drawing which shows the air filling process in the shaping | molding method of the conventional door trim. It is explanatory drawing which shows the state at the time of the injection start of the molten resin in the shaping | molding method of the conventional door trim. It is explanatory drawing which shows the state at the time of the completion of injection | pouring of molten resin in the shaping | molding method of the conventional door trim. It is explanatory drawing which shows the state at the time of discharge | emission of the mold air in the shaping | molding method of the conventional door trim. It is explanatory drawing which shows the state at the time of the core back in the shaping | molding method of the conventional door trim.

  DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of a method for molding a foamed resin molded article and a molding apparatus according to the present invention will be described in detail below with reference to the accompanying drawings. Note that the gist of the present invention is as described in the scope of claims, and the contents of the embodiments described below are merely examples of the present invention.

  FIG. 1 to FIG. 6 show a first embodiment of the present invention. FIG. 1 is a front view showing an automobile door trim having a door trim manufactured by the method of the present invention, and FIG. 2 is a sectional view showing the structure of the door trim. FIG. 3 is an explanatory view showing a schematic configuration of a first embodiment of a molding apparatus used in the method of the present invention, and FIGS. 4 to 6 are explanatory views showing respective steps in the first embodiment of the method of the present invention.

  In FIG. 1 and FIG. 2, the automobile door trim 10 is composed of an upper and lower divided body of a door trim upper 20 and a door trim lower 30. An inside handle unit 11 is attached to the door trim upper 20, and a pull handle 12 and a power window switch unit 13 are attached to an armrest portion on which an occupant places an elbow. On the other hand, the door trim lower 30 is provided with a pocket opening 14 of a door pocket that can accommodate equipment, and a speaker grill 15 is provided on the front side of the door trim lower 30 integrally with the door trim lower 30 or separately.

  Further, as shown in FIG. 2, the door trim upper 20 and the door trim lower 30 are configured by a laminated structure in which a skin 22 is pasted on the surface of a resin core 21, as shown in FIG. 2. Synthetic resins used as the material of the resin core material 21 include polyethylene resins, polypropylene resins, polystyrene resins, polyethylene terephthalate resins, polyvinyl alcohol resins, vinyl chloride resins, polyamide resins, polyacetal resins, polycarbonate resins. A resin, an ionomer resin, an acrylonitrile / butadiene / styrene (ABS) resin, or the like may be selected as appropriate, and a filler such as talc, clay, or wood powder may be mixed into the synthetic resin as desired.

  On the other hand, for the skin 22, a synthetic resin sheet such as a thermoplastic elastomer resin represented by TPO (thermoplastic olefin), or a laminated sheet material with a cushion layer such as polyethylene foam lined on the back surface of the TPO sheet can be used.

  Further, in order to mold the door trim upper 20 into a desired shape, the injection molding method and the mold press molding method are suitable in consideration of mass productivity. That is, the outer skin 22 is set in a molding die, and the resin core material 21 is molded into a desired curved surface shape by injecting and filling the molten resin after the mold clamping or immediately before the mold clamping. The skin 22 can be integrally attached to the surface side.

  On the other hand, as the door trim lower 30, a foamed resin molded product is used in the present invention, and a foamed resin material in which a foaming agent is mixed in a synthetic resin is used. For example, usable synthetic resins include polyethylene resins, polypropylene resins, polystyrene resins, polyethylene terephthalate resins, polyvinyl alcohol resins, vinyl chloride resins, polyamide resins, polyacetal resins, polycarbonate resins, and ionomer resins. The resin is suitably selected from acrylonitrile / butadiene / styrene (ABS) resin and the like. A synthetic resin in which an organic foaming agent such as azodicarbonamide or an inorganic foaming agent such as sodium bicarbonate is mixed is used.

  The door trim 10 shown in FIG. 1 and FIG. 2 has a good product appearance due to the accent effect on the appearance of the door trim upper 20 and the door trim lower 30, and the molding die can be made compact. Constructing the door trim lower 30 from a foamed resin molded product contributes greatly to weight reduction.

  As shown in FIG. 2, the door trim lower 30 has a boss 32 and a clip seat 33, which are functional resin members, integrated at a predetermined position on the back surface of the foamed resin base material 31. The door trim lower 30 obtained by the method of the present invention can freely control the foaming magnification and the product plate thickness, and can improve the degree of modeling freedom, and the product surface has silver streak, foam unevenness, irregularities, etc. In addition, the corners can be sharply shaped and have excellent appearance performance.

  Next, a schematic configuration of the molding apparatus 40 used in the method for molding the door trim lower 30 will be described with reference to FIG. That is, the molding apparatus 40 used in the first embodiment is a molding die 50 in which the mold opening / closing direction is set to the horizontal direction and the material of the foamed resin base material 31 in the door trim lower 30 in the molding die 50. It is composed of an extrusion unit 60 and a die 61 positioned at a predetermined position above the molding die 50 so that the foamed resin sheet S can be suspended.

  More specifically, the molding die 50 is roughly composed of a cavity die 51 that is movable on the product surface side of the door trim lower 30 and a core die 52 that corresponds to the back side of the door trim lower 30 and is on the fixed side. The cavity mold 51 is moved in the horizontal direction by a predetermined stroke by driving the hydraulic cylinder 511, and the cavity mold 51 and the core mold 52 perform mold opening and mold clamping.

  On the other hand, an injection unit 53 is connected to the core mold 52, and a molten resin M is contained in a recess 522 formed on the mold surface of the core mold 52 through a resin passage 521 including a hot runner and a gate provided in the core mold 52. Is injection filled. The concave portion 522 is a position corresponding to the boss 32 and the clip seat 33 that are functional resin members, and is set to match the corresponding shape. In addition, a hot blade 523 for cutting and removing the end material generated when the foamed resin base material 31 is molded is provided on the outer peripheral edge of the parting surface of the core mold 52 with respect to the cavity mold 51. Although the molding die 50 is configured as described above, an extrusion unit 60 and a die 61 are provided above the molding die 50, and when the molding die 50 is in the mold open state, The extrusion unit 60 and the die 61 are positioned at a position where the foamed resin sheet S can be dropped and supplied into the mold.

  Next, each step of molding the door trim lower 30 in the door trim 10 using the molding apparatus 40 shown in FIG. 3 will be described. First, as shown in FIG. 4, a foamed resin sheet S which is a raw material of the foamed resin base material 31 (in this first embodiment, PP with a foaming agent added in polypropylene (PP) resin through an extrusion unit 60 and a die 61, as shown in FIG. A foamed resin sheet) is extruded downward. That is, the foamed resin sheet S is supplied in a hanging shape so as to be positioned between the cavity mold 51 and the core mold 52 in the mold open state. At this time, the foamed resin sheet S is adjusted to an arbitrary foaming ratio. ing.

  Therefore, if the foamed resin sheet S is extruded downward from the extrusion unit 60 and the die 61 and is suspended, it can be automatically supplied between the cavity mold 51 and the core mold 52, and a separate support frame and holding mechanism are required. Therefore, the foamed resin sheet S can be supplied into the molding die 50 easily and inexpensively. Furthermore, when the sheet material is supplied in the horizontal direction, there is a problem that a draw-down phenomenon occurs, and the timing of contact with the mold varies, so that molding defects are easily induced. The method also has the advantage that the draw-down phenomenon can be effectively avoided.

  Then, as shown in FIG. 5, after the foamed resin sheet S is supplied, the cavity mold 51 and the core mold 52 are clamped by driving the hydraulic cylinder 511, and the foamed resin base material 31 is press-molded into a required shape. . At this time, the excess portion of the foamed resin sheet S is cut and removed by the hot blade 523. In the press molding process of the foamed resin base material 31, the drawn pattern may be transferred from the mold surface of the cavity mold 51, and the mold clearance between the cavity mold 51 and the core mold 52 can be set arbitrarily, so that the product The plate thickness can be freely controlled.

  Next, as shown in FIG. 6, the molten resin M is injected and filled into the recess 522 through the resin passage 521 such as a hot runner and a gate from the injection unit 53 connected to the core mold 52, and the boss 32, the clip seat 33, etc. The functional resin member is thermally fused to the back surface of the foamed resin base material 31. Thereafter, after opening the molding die 50, the door trim lower 30 is taken out from the molding die 50, piercing cut processing and terminal processing are performed, and the final product is joined and integrated with the door trim upper 20, thereby FIG. , The door trim 10 shown in FIG. 2 can be manufactured.

  Thus, according to the molding method of the door trim lower 30 according to the method of the present invention, the foamed resin sheet S extruded downward from the extrusion unit 60 and the die 61 is press-molded into a required shape by clamping the molding die 50. Therefore, in addition to being able to arbitrarily adjust the foaming ratio when the foamed resin sheet S is extruded, the product plate thickness can be freely controlled, and in addition, accurate molding and faithfulness can be achieved by press molding. The drawing pattern can be transferred, and conventional problems such as silver streak, foaming unevenness, unevenness and the like can be effectively solved, and the door trim lower 30 having excellent appearance performance can be formed.

  Furthermore, since the foamed resin sheet S can be extruded downward from the extrusion unit 60 and the die 61 and supplied into the molding die 50 in a suspended state, a separate sheet material holding mechanism can be eliminated, and a drawdown (sagging) can be achieved. Since the phenomenon can be avoided, it can be produced easily and inexpensively, and the effect of improving the moldability can be expected.

  FIGS. 7 to 10 show a second embodiment of the present invention, FIG. 7 is an explanatory view showing a schematic configuration of a molding apparatus 40 in the second embodiment, and FIGS. 8 to 10 are molding apparatuses shown in FIG. It is explanatory drawing which shows each process of the shaping | molding method of the door trim lower 30 which uses A. Also in the second embodiment, the door trim lower 30 in the door trim 10 is configured by fusing and integrating the foam resin base 31 and the boss 32 and the clip seat 33 which are functional resin members integrated on the back surface thereof. Since they are the same, the description of the door trim lower 30 which is a molding object is omitted here. In the molding apparatus 40 according to the second embodiment, a heater 70 is newly provided between the extrusion unit 60 and the die 61 and the molding die 50. Since the configuration of the extrusion unit 60, the die 61, and the molding die 50 is the same as that of the first embodiment, the description thereof is also omitted.

  Accordingly, the foamed resin sheet S is heat-treated by the heater 70 in the downward direction extruded from the extrusion unit 60 and the die 61, and is supplied in a suspended state into the molding die 50 in a state of being foamed to an arbitrary magnification. It is a feature.

  Hereinafter, a method for forming the door trim lower 30 using the forming device 40 will be briefly described with reference to FIGS. 8 to 10. As shown in FIG. 8, the door trim lower 30 is directed downward through the extrusion unit 60 and the die 61. The foamed resin sheet S to be extruded is heated to about 200 ° C. by the heater 70, and is adjusted to an arbitrary expansion ratio in this state. The foamed resin sheet S in a heated state is supplied into the molding die 50 in a suspended state between the cavity mold 51 and the core mold 52. Thereafter, as shown in FIG. 9, the cavity mold 51 and the core mold 52 are clamped to shape the foamed resin sheet S into a required shape, and the end material generated during press molding of the foamed resin base material 31 is heated. The foamed resin base material 31 is press-molded into a required shape by cutting and removing with the blade 523.

  Further, as shown in FIG. 10, a recess 522 provided at a predetermined position on the mold surface of the core mold 52 through the resin passage 521 from the injection unit 53 at the same time as the molding of the foamed resin base material 31 or after the molding. As in the first embodiment, the molten resin M is injected and filled, and the boss 32 and the clip seat 33, which are functional resin members, are integrated with the back surface of the foamed resin base material 31 by heat fusion. The foaming ratio and plate thickness of 30 can be arbitrarily adjusted, and the door trim lower 30 having excellent appearance performance can be easily formed.

  In Example 1 and Example 2, although it applied to the door trim lower 30 in the door trim 10 of the upper and lower split structure, it is not limited to this, It can apply to foamed resin molded products in general. Furthermore, although the cavity mold 51 is configured as a movable mold and the core mold 52 is configured as a fixed mold, the cavity mold 51 and the core mold 52 may be reversed depending on the product shape.

10 Automotive door trims 20 Door trim uppers (laminate molding)
21 Resin core material 22 Skin 30 Door trim lower (foamed resin molded product)
31 Foamed resin base material 32 Boss 33 Clip seat 40 Molding device 50 Molding die 51 Cavity mold 511 Hydraulic cylinder 52 Core mold 521 Resin passage 522 Recessed portion 523 Hot blade 53 Injection unit 60 Extruding unit 61 Die 70 Heating heater S Foamed resin sheet M Molten resin

Claims (4)

A foamed resin base material (31) formed by press-molding the foamed resin sheet (S) into a required shape by clamping a molding die (50) composed of a cavity mold (51) and a core mold (52), and this foaming In the molding method of the foamed resin molded product (30) formed by fusing and integrating the functional resin member (32, 33) on the back surface of the resin base material (31),
The foamed resin sheet (S) is extruded downward from the extrusion unit (60) and the die (61) set above the molding die (50), and the cavity mold (51) and the core mold (52) are formed. An extrusion process of the foamed resin sheet (S) for supplying the foamed resin sheet (S) into the molding die (50) by hanging the foamed resin sheet (S) in the space when the mold is in an open state; ,
A foamed resin base material that molds the foamed resin sheet (S) into the mold surface shape of the molding die by clamping the cavity mold (51) and the core mold (52) with the drive direction set to the horizontal direction. 31) the press molding process;
The molten resin (M) is injected and filled from the injection unit (53) connected to the core mold (52) into the recess (522) provided on the mold surface of the core mold (52) through the resin passage (521). An injection molding step of the functional resin member (32, 33) for fusing and integrating the functional resin member (32, 33) at a predetermined position on the back surface of the foamed resin base material (31);
A method for molding a foamed resin molded product comprising:   In the process of extruding the foamed resin sheet (S), a heater (70) is inserted between the molding die (50) and the extrusion unit (60) and the die (61), and the extrusion unit (60) and the die (61 ) The foamed resin sheet (S) extruded downward is heated to a predetermined temperature when passing through the heater (70), and is suspended in the molding die (50) with the foaming ratio adjusted. The method for molding a foamed resin molded product according to claim 1, wherein Foamed resin comprising a foamed resin base material (31) press-molded into a required shape and a functional resin member (32, 33) fused and integrated at a predetermined position on the back surface of the foamed resin base material (31). In the molding device (40) of the molded product (30),
The molding device (40) is extruded downward from the extrusion unit (60) and the die (61), which can extrude the foamed resin sheet (S) downward, and from the die (61), It comprises a molding die (50) comprising a cavity die (51) and a core die (52) in which the driving direction that can press-mold the suspended foamed resin sheet (S) into a required shape is set in the horizontal direction, and the above An injection unit (53) is connected to the core mold (52), and a recess (522) in which molten resin from the injection unit (53) is injected and filled through a resin passage (521) inside the core mold (52). An apparatus for molding a foamed resin molded product, characterized in that it is provided at a position corresponding to the functional resin member (32, 33) on the mold surface of the core mold (52).   Between the molding die (50) and the extrusion unit (60) and the die (61), the foamed resin sheet (S) extruded downward from the die (61) can be softened by heating and adjusted to a desired magnification. The apparatus for molding a foamed resin molded product according to claim 3, wherein a heater (70) is interposed.

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